Refinery Turnaround Planning and Optimization Training Course

Refinery Turnaround Planning and Optimization Training Course

Introduction

Refinery Turnaround Planning and Optimization Training Course is designed to equip oil and gas professionals with advanced knowledge and practical skills for planning, scheduling, executing, and optimizing refinery shutdowns, turnarounds, and major maintenance projects. This training course provides a structured approach to turnaround management, shutdown planning, critical path scheduling, work scope development, resource optimization, risk-based maintenance, and project controls. Participants will explore modern methodologies for defining turnaround objectives, prioritizing maintenance activities, estimating budgets, managing contractors, allocating resources, and establishing realistic schedules. The programme also integrates industry best practices in predictive maintenance, reliability-centred maintenance (RCM), risk-based inspection (RBI), digital maintenance management, and data-driven decision-making to improve turnaround readiness and execution performance.

Through industry-based case studies, group exercises, and realistic refinery scenarios, delegates will examine common challenges such as scope growth, delayed materials, contractor underperformance, equipment failures, and unexpected maintenance discoveries. The training also explores the role of digital twins, computerized maintenance management systems (CMMS), enterprise asset management (EAM), and analytics in strengthening turnaround visibility and control. By the end of the programme, participants will be better equipped to deliver safe, cost-effective, and schedule-driven refinery turnarounds while supporting operational excellence, asset lifecycle optimization, regulatory compliance, and long-term business profitability.

Course Duration

5 days

Course Objectives

By the end of this training course, participants will be able to:

1. Develop comprehensive refinery turnaround strategies aligned with business objectives, production targets, and asset reliability requirements.
2. Apply advanced shutdown planning and scheduling techniques to minimize downtime and maximize operational availability.
3. Establish effective turnaround work scope management processes to control scope growth and prioritize critical maintenance activities.
4. Use critical path method (CPM) and project scheduling tools to identify schedule constraints and optimize turnaround duration.
5. Implement risk-based maintenance, risk-based inspection (RBI), and reliability-centred maintenance (RCM) principles in turnaround preparation.
6. Prepare accurate turnaround budgets, cost estimates, and financial forecasts to improve cost control and expenditure transparency.
7. Optimize workforce planning, contractor management, and resource allocation for efficient turnaround execution.
8. Strengthen process safety management, hazard identification, and operational risk assessment during shutdown and startup activities.
9. Improve materials management, procurement planning, and spare parts availability to prevent execution delays.
10. Apply digital maintenance systems, CMMS, EAM platforms, and project analytics to enhance planning accuracy and turnaround visibility.
11. Monitor turnaround KPIs, earned value management, and schedule performance indicators to support timely corrective action.
12. Develop effective quality assurance, inspection, testing, and mechanical integrity verification procedures.
13. Conduct structured post-turnaround reviews, lessons-learned analysis, and continuous improvement initiatives to enhance future performance.

Target Audience

1. Refinery Operations Managers responsible for plant availability, production continuity, and operational performance.
2. Turnaround and Shutdown Managers overseeing the complete turnaround lifecycle.
3. Maintenance Managers and Engineers responsible for equipment maintenance, work scope development, and execution planning.
4. Project Managers and Project Controls Specialists managing schedules, budgets, resources, and project risks.
5. Reliability Engineers and Asset Integrity Specialists focused on equipment reliability, inspection strategies, and failure prevention.
6. Process Safety and HSE Professionals responsible for safety management, hazard control, and regulatory compliance.
7. Procurement, Materials, and Logistics Professionals coordinating spares, equipment, contractors, and turnaround supplies.
8. Planning Engineers, Supervisors, and Contractor Coordinators responsible for detailed work packs, workforce scheduling, and field execution.

Course Modules

Module 1: Fundamentals of Refinery Turnaround Management

• Understanding refinery turnaround concepts, objectives, and operational significance.
• Examining the turnaround lifecycle from initial planning to post-startup review.
• Defining turnaround governance, leadership responsibilities, and decision-making structures.
• Establishing turnaround strategies based on asset criticality and business priorities.
• Aligning maintenance requirements with production schedules and refinery performance targets.
• Case Study: Evaluate a refinery turnaround that exceeded its planned duration and identify weaknesses in governance, preparation, and execution.

Module 2: Turnaround Scope Development and Work Identification

• Developing comprehensive turnaround work lists from maintenance and inspection requirements.
• Applying equipment criticality analysis to prioritize maintenance and repair activities.
• Integrating statutory inspections, preventive maintenance, and corrective maintenance tasks.
• Managing scope freeze, scope changes, and additional work discovered during execution.
• Developing work breakdown structures and standardized job plans for turnaround activities.
• Case Study: Develop and prioritize a turnaround scope for a refinery processing unit with multiple equipment defects and limited shutdown time.

Module 3: Advanced Turnaround Scheduling and Critical Path Optimization

• Applying critical path method (CPM) to establish realistic turnaround schedules.
• Developing detailed work packs, activity sequences, milestones, and dependencies.
• Identifying schedule bottlenecks and optimizing parallel work opportunities.
• Using resource-loaded schedules and productivity assumptions to improve execution planning.
• Implementing schedule risk analysis, contingency planning, and recovery strategies.
• Case Study: Optimize a delayed hydroprocessing unit turnaround by revising task sequencing, resource allocation, and critical path activities.

Module 4: Turnaround Cost Estimation and Budget Control

• Developing detailed cost estimates for labour, contractors, materials, equipment, and services.
• Establishing turnaround budgets, contingency provisions, and cost baselines.
• Applying earned value management (EVM) to assess cost and schedule performance.
• Monitoring expenditure, managing variations, and controlling unplanned maintenance costs.
• Evaluating cost-saving opportunities without compromising safety or equipment integrity.
• Case Study: Investigate a refinery turnaround with significant budget overruns and propose corrective measures to improve financial control.

Module 5: Risk Management, Process Safety, and Regulatory Compliance

• Conducting turnaround risk assessments, HAZID, and job safety analysis (JSA).
• Managing permit-to-work systems, isolation procedures, and lockout/tagout (LOTO).
• Planning confined-space entry, hot work, work at height, and simultaneous operations.
• Integrating risk-based inspection (RBI) and mechanical integrity requirements into turnaround plans.
• Establishing emergency preparedness, incident reporting, and safe startup procedures.
• Case Study: Assess safety risks during simultaneous maintenance activities in a refinery unit and develop an integrated risk mitigation plan.

Module 6: Resource, Contractor, Procurement, and Materials Optimization

• Forecasting manpower requirements and developing competency-based workforce plans.
• Evaluating contractor capability, performance standards, and mobilization readiness.
• Optimizing spare parts availability, procurement lead times, and inventory management.
• Coordinating tools, lifting equipment, scaffolding, temporary facilities, and specialist services.
• Managing contractor productivity, site logistics, and interdepartmental coordination.
• Case Study: Resolve delays caused by missing critical valves, inadequate contractor staffing, and inefficient material distribution during a refinery shutdown.

Module 7: Digital Turnaround Management and Performance Monitoring

• Applying computerized maintenance management systems (CMMS) and enterprise asset management (EAM) platforms.
• Using digital dashboards to monitor work completion, costs, resources, and schedule deviations.
• Integrating inspection findings, equipment histories, and maintenance records into turnaround planning.
• Exploring predictive analytics, digital twins, and AI-assisted maintenance planning applications.
• Defining turnaround KPIs, reporting structures, and escalation mechanisms for performance control.
• Case Study: Use a simulated turnaround dashboard to identify schedule slippage, labour productivity issues, and emerging cost overruns.

Module 8: Turnaround Execution, Startup, and Continuous Improvement

• Coordinating daily turnaround meetings, field supervision, and progress reporting.
• Managing quality inspections, testing, equipment reinstatement, and completion certification.
• Conducting pre-startup safety reviews (PSSR) and verifying operational readiness.
• Measuring turnaround performance against safety, cost, duration, quality, and reliability targets.
• Developing lessons-learned reports and continuous improvement plans for future shutdowns.
• Case Study: Review a refinery restart following a major turnaround and develop an improvement plan addressing startup delays, incomplete documentation, and recurring equipment failures.

Training Methodology

• Interactive lectures and presentations.
• Group discussions and brainstorming sessions.
• Hands-on exercises using real-world datasets.
• Role-playing and scenario-based simulations.
• Analysis of case studies to bridge theory and practice.
• Peer-to-peer learning and networking.
• Expert-led Q&A sessions.
• Continuous feedback and personalized guidance.

Register as a group from 3 participants for a Discount

Send us an email: info@datastatresearch.org or call +254724527104 

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

 We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to DATASTAT CONSULTANCY LTD account, as indicated in the invoice so as to enable us prepare better for you.